Spray texture material compositions, systems, and methods with anti-corrosion characteristics

ABSTRACT

A system for dispensing texture material in a desired spray pattern that substantially matches an existing texture pattern on a target surface has a container assembly, an actuator assembly, and a concentrate comprising a solvent/carrier comprising water, wall texture material comprising at least one filler and a resin/binder, a first anti-corrosion material, where the first anti-corrosion material is a phosphate ester, and a second anti-corrosion material, where the second anti-corrosion material is sodium nitrite. At least one of the first and second anti-corrosion materials forms a film on the inner surface of the container assembly while the concentrate is stored within the container assembly. The film inhibits corrosion of the corrodible material forming at least part of the inner surface of the container assembly. The first and second anti-corrosion materials together comprise 0.125-7.00% by weight of the concentrate.

RELATED APPLICATIONS

This application (Attorney's Ref. No. P218024C1) is a continuation ofU.S. patent application Ser. No. 14/338,231 filed Jul. 22, 2014,currently pending.

U.S. patent application Ser. No. 14/338,231 is a continuation of U.S.patent application Ser. No. 14/047,195 filed Oct. 7, 2013, now U.S. Pat.No. 8,784,942, which issued on Jul. 22, 2014.

U.S. patent application Ser. No. 14/047,195 is a continuation of U.S.patent application Ser. No. 13/610,743 filed Sep. 11, 2012, now U.S.Pat. No. 8,551,572, which issued Oct. 8, 2013.

U.S. patent application Ser. No. 13/610,743 is a continuation of U.S.patent application Ser. No. 13/396,538 filed Feb. 14, 2012, nowabandoned.

U.S. patent application Ser. No. 13/396,538 is a continuation of U.S.patent application Ser. No. 13/181,326 filed Jul. 12, 2011, nowabandoned.

U.S. patent application Ser. No. 13/181,326 is a continuation of U.S.patent application Ser. No. 12/837,254 filed Jul. 15, 2010, nowabandoned.

U.S. patent application Ser. No. 12/837,254 is a continuation of U.S.patent application Ser. No. 12/080,096 filed Mar. 31, 2008, nowabandoned.

U.S. patent application Ser. No. 12/080,096 claims benefit of U.S.Provisional Patent Application Ser. No. 60/922,041 filed Apr. 4, 2007.

The contents of all related patent applications listed above areincorporated herein by reference.

TECHNICAL FIELD

The present invention relates to materials for forming a texturedcoating on a target surface and, more particularly, to compositions ofwater-based texture materials and systems and methods for dispensingwater-based texture materials from either aluminum or tin-plated steelcontainers.

BACKGROUND

The surfaces of drywall materials defining wall and ceiling surfaces arecommonly coated with texture materials. Texture materials are coatingsthat are deposited in discrete drops that dry to form a bumpy, irregulartexture on the destination surface. Texture materials are commonlyapplied using a hopper gun connected to a source of pressurized air.However, when only a small area is to be coated or an existing texturedsurface is repaired, texture materials are typically applied using anaerosol dispensing system.

An aerosol dispensing system for dispensing texture material typicallycomprises a container assembly, a valve assembly, and an outletassembly. The container assembly contains the texture material and apropellant material. The propellant material pressurizes the texturematerial within the container assembly. The valve assembly is mounted tothe container assembly in a normally closed configuration but can beplaced in an open configuration to define a dispensing path along whichthe pressurized texture material is forced out of the container assemblyby the propellant material. Displacement of the outlet assembly placesthe valve assembly in the open configuration. The outlet assemblydefines a portion of the outlet path and is configured such that thetexture material is applied to the destination surface in an appliedtexture pattern.

The texture material dispensed by an aerosol dispensing system mayemploy a solvent base, a water base, or a base containing a combinationof water and water soluble solvents. A solvent based texture materialdries quickly but can be malodorous and may require the use ofcomplementary solvent cleaners for clean up. A water based texturematerial is typically not malodorous and can be cleaned using water butcan take significantly longer to dry. A water/solvent based texturematerial can be cleaned using water, is typically not unacceptablymalodorous, and has a dry time somewhere between solvent based and waterbased texture materials.

The propellant used by aerosol dispensing systems for texture materialsmay simply be a compressed inert gas such as air or nitrogen. Moretypically, the propellant used by aerosol dispensing systems is abi-phase propellant material, including mixtures of volatilehydrocarbons such as propane, n-butane, isobutane, dimethyl ether (DME),and methylethyl ether.

At room temperature, bi-phase propellant materials typically exist inboth liquid and vapor states within the container assembly. Prior touse, the vapor portion of the bi-phase propellant material ispressurized to an equilibrium pressure. When the valve assembly isplaced in its open configuration, the vapor portion of the bi-phasepropellant material forces the texture material out of the containerassembly along the dispensing path.

When the valve assembly returns to its closed position, part of theliquid portion of the bi-phase propellant material changes to the vaporstate because of the drop in pressure within the container assembly. Thevapor portion of the propellant material returns the pressure within thecontainer assembly to the equilibrium value in preparation for the nexttime texture material is to be dispensed from the aerosol dispensingsystem.

The container assembly typically comprises a metal tube structure formedby a rectangular metal sheet that is rolled and joined at twooverlapping edges to form a seam. A bottom cap and end cap are welded orcrimped onto the tube structure. The valve assembly and the outletassembly are typically supported by the end cap.

Aerosol container assemblies are typically made of either tin-platedsteel or aluminum. Aluminum container assemblies are typically used forwater based or water/solvent based texture materials because the waterin the formulation promotes corrosion and aluminum is less susceptibleto corrosion. However, the costs and availability of aluminum andtin-plated steel aerosol container assemblies may differ.

The need thus exists for formulations of either water based orwater/solvent based texture materials that may be used in eitheraluminum or tin-plated steel aerosol container assemblies withoutsignificant risk of corrosion.

SUMMARY

The present invention may also be embodied as a system for dispensingtexture material in a desired spray pattern that substantially matchesan existing texture pattern on a target surface comprising a containerassembly, an actuator assembly, and a concentrate. The containerassembly defining an inner surface formed at least in part of acorrodible material. The actuator assembly defines an outlet openinghaving an adjustable cross-sectional area. The concentrate comprises asolvent/carrier comprising water, wall texture material comprising atleast one filler and a resin/binder, a first anti-corrosion material,where the first anti-corrosion material is a phosphate ester, and asecond anti-corrosion material, where the second anti-corrosion materialis sodium nitrite. The concentrate is disposed within the containerassembly such that the water is exposed to the inner surface of thecontainer assembly. At least one of the first and second anti-corrosionmaterials forms a film on the inner surface of the container assemblywhile the concentrate is stored within the container assembly, where thefilm inhibits corrosion of the corrodible material forming at least partof the inner surface of the container assembly. The concentrate passesthrough the outlet opening in a spray pattern that forms the desiredtexture pattern on the target surface. The first and secondanti-corrosion materials together comprise 0.125-7.00% by weight of theconcentrate.

The present invention may also be embodied as a texture materialconcentrate to be dispensed in a desired spray pattern from a containerassembly defining an inner surface formed at least in part of acorrodible material using an actuator assembly defining an outletopening having an adjustable cross-sectional area, where the desiredspray pattern that substantially matches an existing texture pattern ona target surface. The texture material concentrate comprises asolvent/carrier comprising water, wall texture material comprising atleast one filler and a resin/binder, a first anti-corrosion material,where the first anti-corrosion material is a phosphate ester, and asecond anti-corrosion material, where the second anti-corrosion materialis sodium nitrite. The concentrate is disposed within the containerassembly such that the water is exposed to the inner surface of thecontainer assembly. At least one of the first and second anti-corrosionmaterials forms a film on the inner surface of the container assemblywhile the concentrate is stored within the container assembly, where thefilm inhibits corrosion of the corrodible material forming at least partof the inner surface of the container assembly. The concentrate passesthrough the outlet opening in a spray pattern that forms the desiredtexture pattern on the target surface. The first and secondanti-corrosion materials together comprise 0.125-7.00% by weight of theconcentrate.

The present invention may also be embodied as a method for dispensingtexture material in a desired spray pattern that substantially matchesan existing texture pattern on a target surface comprising the followingsteps. A container assembly defining an inner surface formed at least inpart of a corrodible material is provided. An actuator assembly definingan outlet opening having an adjustable cross-sectional area is supportedrelative to the container assembly. A concentrate is arranged within thecontainer assembly. The concentrate comprises a solvent/carriercomprising water, wall texture material comprising at least one fillerand a resin/binder, a first anti-corrosion material, where the firstanti-corrosion material is a phosphate ester, and a secondanti-corrosion material, where the second anti-corrosion material issodium nitrite. The first and second anti-corrosion materials togethercomprise 0.125-7.00% by weight of the concentrate. The concentrate isarranged within the container assembly such that the water is exposed tothe inner surface of the container assembly and at least one of thefirst and second anti-corrosion materials forms a film on the innersurface of the container assembly while the concentrate is stored withinthe container assembly, where the film inhibits corrosion of thecorrodible material forming at least part of the inner surface of thecontainer assembly. The actuator assembly is operated such that theconcentrate passes through the outlet opening in a spray pattern thatforms the desired texture pattern on the target surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a section view of a first example aerosol dispensing systemfor texture material of the present invention;

FIGS. 2A-2B are side elevation views depicting the process of using theaerosol dispensing system of FIG. 1 to apply texture material to adestination wall surface;

FIG. 3 is a section view of a second example aerosol dispensing systemfor texture material of the present invention; and

FIGS. 4A-4B are side elevation views depicting the process of using theaerosol dispensing system of FIG. 3 to apply texture material to adestination ceiling surface.

DETAILED DESCRIPTION

Referring initially to FIG. 1 of the drawing, depicted therein is anexample aerosol dispensing system 20 constructed in accordance with, andembodying, the principles of the present invention. The example aerosoldispensing system 20 comprises a container assembly 22, a valve assembly24, and an outlet assembly 26. The container assembly 22 and valveassembly 24 define a main chamber 28.

The main chamber 28 contains a liquid material 30 and a vapor material32. The liquid material 30 comprises texture material and propellantmaterial in liquid form. The vapor material 32 comprises propellantmaterial in vapor form. The liquid material 30 comprises propellantmaterial in liquid form and a texture material concentrate. Thecombination of the liquid material 30 and the vapor material 32 in thecontainer assembly 22 will be referred to as the contained material 34.

When the valve assembly 24 is in a closed configuration, the flow offluid out of the main chamber 28 is substantially prevented. However,the vapor material 32 pressurizes the liquid material 30 within the mainchamber 28 such that, when the valve assembly 24 is in an openconfiguration, the vapor material 32 forces the liquid material 30 outof the main chamber 28.

As perhaps best shown in FIG. 1, the example container assembly 22comprises a main member 40, a bottom cap 42, and an end cap 44 formed oftin-plated steel. The tin-plated steel used to form the main member 40,bottom cap 42, and end cap 44 comprises a thin sheet of steel coated onone side by an even thinner layer (approximately 0.5 microns) of tin.

The main member 40 is a rectangular sheet that is rolled into a cylinderand welded along a seam 50 to define first and second end openings 52and 54. The bottom cap 42 is a shaped tin-plated steel member that iscrimped onto the cylindrical main member 40 to seal the first endopening 52. The end cap 44 is also a shaped tin-plated steel memberdefining a mounting opening 56; the end cap 44 is crimped onto the mainmember 40 such that fluid may not flow through the second opening 54between the end cap 44 and the main member 40. The main member 40,bottom cap 42, and end cap 44 define an interior metal surface 58 of thecontainer assembly 22.

With the bottom cap 42 covering the first opening 52, the end cap 44covering the second opening 54, and the valve assembly 24 supported bythe end cap 44, the aerosol dispensing system 20 defines the mainchamber 28.

Because the interior metal surface 58 of the container assembly 22 ismetal and is thus susceptible to corrosion, the texture materialconcentrate is formulated to have anti-corrosion properties. The exampletexture material concentrate is generally formulated as follows.

General Example of Texture Material Concentrate

FIRST SECOND PREFERRED PREFERRED COMPONENT RANGE RANGE solvent/carrier30-60% 25-65% resin/binder 4.5-5.5% 3-7% fillers 40-60% 20-70% additives0.250-0.750% 0.000-1.000% first anti-corrosion 0.5-2%   0.1-5.0%material second anti-corrosion 0.05-1%   0.025-2.0%  material

The texture material concentrate described in the table set forth aboveis combined in the container assembly 22 with the propellant material toobtain the contained material 34. The preferred amount of propellantmaterial used to form the example dispensing system 20 is approximately12.5% of the texture material concentrate by weight and is preferablywithin a first preferred range of 10-15% and is in any event preferablywithin a second preferred range of 5-20%.

In the context of the example container assembly 22 comprisingtin-plated steel components, the first and second anti-corrosionmaterials are included to promote passive corrosion behavior of themetal interior surface 58 of the container assembly 22 in contact withthe texture material concentrate. Passive corrosion behavior occurs whenthe interaction between a metal structure and the environment forms athin protective film on the surface of the metal structure. Passivecorrosion produces essentially no corrosion of the metal structure andthus is very desirable.

In the example texture material concentrate, the first anti-corrosionmaterial is Elfugin, which is an anionic, phosphate ester. Elfugin is aproprietary product sold by Clariant Paper Chemicals as an antistaticfor application to paper products. In the general example describedabove, approximately 1.00% (±5%) of the first anti-corrosion material ispreferably used. The second anti-corrosion material of the exampletexture material concentrate is sodium nitrite. In the general exampledescribed above, approximately 0.100% (±5%) or 0.250% (±5%) of the firstanti-corrosion material is preferably used, depending upon the nature ofthe remaining components of the texture material concentrate andpropellant.

The texture material concentrate is preferably formulated and combinedwith propellant material as follows. The first and second anti-corrosionmaterials are initially dissolved in the water. The remaining materialsare then mixed with the water solution to obtain the texture materialconcentrate.

The bottom cap 42 is crimped onto the main member 40 to form a containersubassembly 22 a. The valve assembly 24 is combined with the end cap 44to form a cap subassembly 22 b. The texture material concentrate isplaced within the container subassembly 22 a. The cap subassembly 22 bis crimped onto the container subassembly 22 a to form the containerassembly 22. The propellant material is then introduced into thecontainer assembly 22 through the valve assembly 24. The outlet assembly26 is then engaged with the valve assembly to form the aerosoldispensing system 20.

With the foregoing general understanding of the present invention, thedetails of several example formulations of the texture materialconcentrate and the construction and use of the example aerosoldispensing system 20 will now be described in further detail.

As described above, the present invention is of particular significancewhen applied to aerosol dispensing systems for dispensing texturematerial. Texture materials are sold in different forms depending uponsuch factors as dry time, ease of application, and the type of texturepattern desired. Set forth below are four tables containing formulationsof example texture material concentrates.

The example contained materials incorporating the following texturematerial concentrates are preferably formed by first combining the firstand second anti-corrosion materials with the water. The remainingmaterials are then mixed into the combination of the water and theanti-corrosion materials to form the texture material concentratesidentified in the tables below. The resulting texture materialconcentrate is then mixed with the propellant material to form thecontained material as generally described above.

First Example of Texture Material Concentrate

When sprayed onto a target surface as will be described in furtherdetail below, the first example texture material concentrate forms whatis commonly referred to as a “knockdown” spray texture pattern. Aknockdown spray texture is formed by a bumpy, irregular texture patternthat is lightly worked with a tool after application to the targetsurface such that the tops of the bumps formed by the texture materialare flattened.

FIRST SECOND PREFERRED PREFERRED COMPONENT PREFERRED RANGE RANGEsolvent/carrier (water) 48.72% 43-53% 38-58% first anti-corrosion  1.0%0.5-2.0% 0.1-5.0% material (Elfugin) second anti-corrosion  0.25%0.05-1.0%  0.025-2%    material (Sodium Nitrite) additive (biocide) 0.10% 0.05-0.50% 0.25-0.10% Homax Wall Texture 50.93 46-56% 41-61%

In the foregoing example, the amounts of the first and secondanti-corrosion materials are preferably held to tolerances ofsubstantially ±5% of the amounts specified in the foregoing table.

The Homax Wall Texture ingredient is a proprietary mixture supplied tothe Applicant by Hamilton Materials Northwest. Generally speaking, theHomax Wall Texture ingredient comprises a binder (starch), pigments likecalcium carbonate, talc, mica, attapulgite clay, and possibly others.Additionally, this type of material typically comprises a biocide anddefoamers.

The ratio of the first example contained material to propellant shouldbe within a first range of approximately 7:1 to 15:1 and in any eventshould be within a second range of approximately 5:1 to 20:1. To obtainthe example contained material 34, one part DME (propellant) is combinedwith 9.42 parts of the first example texture material described in theforegoing table.

Second Example of Texture Material Concentrate

When sprayed onto a target surface as will be described in furtherdetail below, the second example texture material concentrate forms whatis commonly referred to as an “orange peel” spray texture pattern. Anorange peel spray texture comprises rounded, irregular bumps on thetarget surface that generally resemble the surface of an orange. Byvarying the parameters of the spray pattern, the size and depth of thebumps can be varied to obtain different aesthetic looks. The secondexample texture material concentrate further changes color while dryingsuch that the color indicates when the texture material is sufficientlydry for the application of a top coat such as a coat of primer or paint.

FIRST SECOND PREFERRED PREFERRED COMPONENT PREFERRED RANGE RANGEsolvent/carrier 34.965% 30-40% 25-45% (water, proponal) firstanti-corrosion 1.000% 0.5-2.0% 0.1-5.0% material (Elfugin) second 0.100%0.05-1.0%  0.025-2%    anti-corrosion material (Sodium Nitrite)additives (biocides, 0.530% 0.250-0.750% 0.000%-1.000%    defoamer,dispersant) resin/binder (latex) 5.127% 4.100-6.100% 2.600-7.600% filler(thickener, 58.275% 53-63% 48-68% clay, talc, calcium carbonate) colorchange agent 0.003% 0.002-0.003% 0.001-0.010% (Bromothymol Blue)

In the foregoing example, the amounts of the first and secondanti-corrosion materials are preferably held to the followingtolerances. The amount of the first anti-corrosion material used shouldbe substantially within ±5% of the amount specified in the foregoingtable. The amount of the first anti-corrosion material used should besubstantially within +0% and -5% of the amount specified in theforegoing table.

The ratio of the second example contained material to propellant shouldbe within a first range of approximately 7:1 to 15:1 and in any eventshould be within a second range of approximately 5:1 to 20:1. To obtainthe example contained material 34, one part DME (propellant) is combinedwith 9.42 parts of the first example texture material described in theforegoing table.

Third Example of Texture Material Concentrate

When sprayed onto a target surface as will be described in furtherdetail below, the second example texture material concentrate forms whatan orange peel spray texture pattern. As with the second example texturematerial concentrate described above, varying the parameters of thespray pattern varies the size and depth of the bumps forming the orangepeel pattern to obtain different aesthetic looks.

FIRST SECOND PREFERRED PREFERRED COMPONENT PREFERRED RANGE RANGEsolvent/carrier 34.970% 30-40% 25-45% (water, propanol) firstanti-corrosion 1.000% 0.500-2.000% 0.100-5.000% material (Elfugin)second 0.250% 0.050-1.000% 0.025-2.00%  anti-corrosion material (SodiumNitrite) Additives (biocides, 0.530% 0.250-0.750% 0.000%-1.000%   defoamer, dispersant) resin/binder (latex) 5.127% 4.100-6.100%2.600-7.600% Filler (thickener, 58.123% 53-63% 48-68% clay, talc,calcium carbonate)

In the foregoing example, the amounts of the first and secondanti-corrosion materials are preferably held to tolerances ofsubstantially ±5% of the amounts specified in the foregoing table.

The ratio of the third example contained material to propellant shouldbe within a first range of approximately 7:1 to 15:1 and in any eventshould be within a second range of approximately 5:1 to 20:1. To obtainthe example contained material 34, one part DME (propellant) is combinedwith 9.42 parts of the first example texture material described in theforegoing table.

Fourth Example of Texture Material Concetrate

When sprayed onto a target surface as will be described in furtherdetail below, the fourth example texture material concentrate forms whatis commonly referred to as a “popcorn” or “acoustic” spray texturepattern. A popcorn or acoustic spray texture pattern comprises visibleparticulates that are adhered to the target surface by binders in thebase. The particulates somewhat resemble popcorn and provide acousticdampening qualities that reduce echoing off of the target surface onwhich the popcorn or acoustic spray texture pattern is formed.

FIRST SECOND PREFERRED PREFERRED COMPONENT PREFERRED RANGE RANGEsolvent/carrier (water) 57.05% 52-62% 47-67% first anti-corrosion 1.02%0.500-2.000% 0.100-5.000% material (Elfugin) second anti-corrosion 0.25%0.050-1.000% 0.025-2.00%  material (Sodium Nitrite) Additives (biocide)0.10% 0.050-0.500% 0.250-0.100% Homax Wall Texture 40.76% 36-46% 31-51%particulate (Melamine 0.82% 0.6-1.5% 0.25-5.0%  Foam)

In the foregoing example, the amounts of the first and secondanti-corrosion materials are preferably held to tolerances ofsubstantially ±5% of the amounts specified in the foregoing table.

The ratio of the fourth example contained material to propellant shouldbe within a first range of approximately 12:1 to 15:1 and in any eventshould be within a second range of approximately 10:1 to 20:1. To obtainthe example contained material 34, one part DME (propellant) is combinedwith 13.29 parts of the fourth example texture material described in theforegoing table.

Referring again to FIG. 1 of the drawing, the details of constructionand operation of the example dispensing system 20 will now be describedin further detail.

The example valve assembly 24 comprises a valve housing 60, a valve seat62, a valve member 64, and a valve spring 66. The end cap 44 supportsthe valve housing 60 and the valve seat 62 adjacent to the mountingopening 56. The valve housing 60 supports the valve spring 66 such thatthe valve spring 66 biases the valve member 64 against the valve seat 62in a normally closed position. An intake tube 68 extends from the valvehousing 60 to the end of the main member 40 closed by the bottom cap 42.

The outlet assembly 26 comprises an actuator member 70, a resilientmember 72, and a clamp member 74. The actuator member defines a stemportion 76 and a plurality of finger portions 78. The stem portion 76extends through the mounting opening 56 and engages the valve member 64.The actuator member 70 supports the resilient member 72 such that theresilient member 72 is held within the finger portions 78. The clampmember 74 engages the actuator member 70 such that displacement of theclamp member 74 relative to the actuator member 70 bends the fingerportions 78 towards each other to deform the resilient member 72.

A dispensing path 80 extends between an inlet opening 82 defined by theintake tube 68 and an outlet opening 84 defined by the resilient member72. Fluid is prevented from flowing along the dispensing path 80 whenthe valve assembly 24 is in the closed configuration as defined above.Fluid may flow along the dispensing path 80 when the valve assembly 24is in the open configuration. The spray pattern of liquid flowing out ofthe main chamber 28 through the outlet opening 84 may be varied bydeforming the resilient member 72 as described above.

More specifically, the valve spring 66 normally biases the valve member64 against the valve seat 62 to close the dispensing path 80. When theactuator member 70 is displaced towards the container assembly 22, thevalve member 64 is displaced away from the valve seat 62 against theforce of the valve spring 66 to place the valve assembly 24 in its openconfiguration. In this open configuration, the example dispensing path80 extends through a first passageway 90 defined by the intake tube 68,a valve chamber 92 defined by the valve housing 60, a gap 94 betweenvalve member 64 and the valve seat 62, a second passageway 96 defined bythe actuator member 70, and a fourth passageway 98 defined by theresilient member 72.

Turning now to FIGS. 2A-2B of the drawing, depicted therein is anexample of use of the example dispensing system 20 described above. Theexample dispensing system 20 is used to apply texture material to a wallmember 120 defining a target surface portion 122. In the case of arepair to the wall member 120, existing spray texture material 124typically surrounds the target surface portion 122.

Initially, the dispensing system 20 is arranged such that the outletopening 84 faces the target surface portion 122. The actuator member 70is then displaced to place the valve assembly 24 in its openconfiguration. The pressurized propellant material causes a portion ofthe contained material 34 to be dispensed from the container assembly 22through the dispensing path 80.

Because of the formulation of the contained material 34 and the geometryof the resilient member 72, the contained material exits the containerassembly 22 in a spray 130 comprising discrete droplets 132. Thedroplets 132 are deposited onto the target surface 122 to form a texturecoating 134 in an applied texture pattern. The texture coating 134 isinitially wet but dries when exposed to air. In the case of a knockdowntexture pattern, the texture coating 134 is worked to flatten the highpoints of the texture pattern when still wet. In the case of a colorchanging texture material, the texture coating 134 will be one colorwhen wet and another color when dry.

By appropriately selecting the cross-sectional area of the outletopening 84, the applied texture pattern of the texture coating 134 canbe formed such that the applied texture pattern substantially matchesthe existing pattern of the existing texture material 124.

The popcorn or acoustic texture material described above is bestdispensed using a second example dispensing system 220 as depicted inFIG. 3. The aerosol dispensing system 220 comprises a container assembly222, a valve assembly 224, and an outlet assembly 226. The containerassembly 222 and valve assembly 224 define a main chamber 228.

The main chamber 228 contains a liquid material 230 and a vapor material232. The liquid material 230 comprises texture material and propellantmaterial in liquid form. The vapor material 232 comprises propellantmaterial in vapor form. The liquid material 230 comprises propellantmaterial in liquid form and a texture material concentrate. Thecombination of the liquid material 230 and the vapor material 232 in thecontainer assembly 222 will be referred to as the contained material234. FIG. 3 further illustrates that the contained material 234comprises particulate material 238 as identified in the table abovedescribing the example popcorn or acoustic texture material concentrate.

When the valve assembly 224 is in a closed configuration, the flow offluid out of the main chamber 228 is substantially prevented. However,the vapor material 232 pressurizes the liquid material 230 within themain chamber 228 such that, when the valve assembly 224 is in an openconfiguration, the vapor material 232 forces the liquid material 230 outof the main chamber 228.

As perhaps best shown in FIG. 3, the example container assembly 222comprises a main member 240, a bottom cap 242, and an end cap 244 formedof tin-plated steel. The tin-plated steel used to form the main member240, bottom cap 242, and end cap 244 comprises a thin sheet of steelcoated on one side by an even thinner layer (approximately 0.5 microns)of tin.

The main member 240 is a rectangular sheet that is rolled into acylinder and welded along a seam 250 to define first and second endopenings 252 and 254. The bottom cap 242 is a shaped tin-plated steelmember that is crimped onto the cylindrical main member 240 to seal thefirst end opening 252. The end cap 244 is also a shaped tin-plated steelmember defining a mounting opening 256; the end cap 244 is crimped ontothe main member 240 such that fluid may not flow through the secondopening 254 between the end cap 244 and the main member 240. The mainmember 240, bottom cap 242, and end cap 244 define an interior metalsurface 258 of the container assembly 222.

With the bottom cap 242 covering the first opening 252, the end cap 244covering the second opening 254, and the valve assembly 224 supported bythe end cap 244, the aerosol dispensing system 220 defines the mainchamber 228.

The bottom cap 242 is crimped onto the main member 240 to form acontainer subassembly 222 a. The valve assembly 224 is combined with theend cap 244 to form a cap subassembly 222 b. The texture materialconcentrate is placed within the container subassembly 222 a. The capsubassembly 222 b is crimped onto the container subassembly 222 a toform the container assembly 222. The propellant material is thenintroduced into the container assembly 222 through the valve assembly224. The outlet assembly 226 is then engaged with the valve assembly toform the aerosol dispensing system 220.

The example valve assembly 224 comprises a valve housing 260, a valveseat 262, and a stem member 264. The valve seat 262 defines a deformableportion 266. The end cap 244 supports the valve housing 260 and thevalve seat 262 adjacent to the mounting opening 256. The valve housing260 supports the deformable portion 266 such that the deformable portion266 biases the stem member 264 against the valve seat 262 in a normallyclosed position. An intake tube 268 extends from the valve housing 260to the end of the main member 240 closed by the bottom cap 242.

The outlet assembly 226 comprises an actuator member 270. The actuatormember 270 is threaded onto a connecting portion 272 of the stem member264. The stem member 264 further defines a valve portion 274 and a valveopening 276. The stem member 264 extends through the valve seat 262 suchthat the valve seat 262 supports the stem member 264 within the mountingopening 256. In particular, the stem member 264 extends through themounting opening 256 such that the valve portion 274 is in contact withthe valve seat 262 when the valve assembly 224 is in its closedconfiguration and not in contact with the valve seat 262 when the valveassembly 224 is in its opening configuration.

A dispensing path 280 extends between an inlet opening 282 defined bythe intake tube 268 and an outlet opening 284 in the actuator 270. Fluidis prevented from flowing along the dispensing path 280 when the valveassembly 224 is in the closed configuration as defined above. Fluid mayflow along the dispensing path 280 when the valve assembly 224 is in theopen configuration. The outlet member 270 is configured to define theoutlet opening 284 such that the spray pattern of liquid flowing out ofthe main chamber 228 through the outlet opening 282 is substantiallyfan-shaped.

More specifically, the deformable portion 266 of the valve seat 262frictionally engages the stem member 264 such that the deformableportion 266 normally biases the stem member 264 to cause the valveportion 274 to engage the valve seat 262, thereby closing the dispensingpath 280. When the actuator member 270 is displaced towards thecontainer assembly 222, the stem member 264 is displaced, deforming thedeformable portion 266, such that the valve portion 274 disengages fromthe valve seat 262 against the force of the deformable portion 266 toplace the valve assembly 224 in its open configuration.

The deformable portion 266 may be replaced with an external or internalspring member that similarly biases the valve assembly 224 into theclosed configuration.

In the open configuration, the example dispensing path 280 extendsthrough a first passageway 290 defined by the intake tube 268, a valvechamber 292 defined by the valve housing 260, a gap 294 between stemmember 264 and the valve seat 262, the valve opening 276, and an outletpassageway 296 defined by the actuator member 270.

The actuator member 270 is configured to define a fan shaped outletportion 298 of the outlet passageway 296 that forms a spray patternappropriate for depositing the popcorn or acoustic texture material onthe target surface in a desired texture pattern.

FIGS. 4A and 4B illustrate that the actuator member 270 is alsoconfigured such that the spray pattern may be directed upwards becausepopcorn or acoustic texture material is typically applied only toceiling surfaces. In particular, FIG. 4A illustrates a wall member 320defining a target surface portion 322. In the case of a repair to thewall member 320, existing spray texture material 324 typically surroundsthe target surface portion 322.

Initially, the dispensing system 20 is arranged such that the outletportion 298 of the outlet passageway 296 faces the target surfaceportion 322. The actuator member 270 is then displaced to place thevalve assembly 224 in its open configuration. The pressurized propellantmaterial causes a portion of the contained material 234 to be dispensedfrom the container assembly 222 through the dispensing path 280.

The contained material exits the container assembly 22 in a spray 330comprising discrete droplets 332 and the particulate material 238. Thedroplets 332 are deposited onto the target surface 322 to form a texturecoating 334 in an applied texture pattern. The particulate material 238is bonded by the texture coating 234 to the target surface 322. Thetexture coating 334 is initially wet but dries when exposed to air. Theapplied texture pattern of the texture coating 334 can be formed suchthat the applied texture pattern substantially matches the existingpattern of the existing texture material 324.

The scope of the present invention should be determined by the claimsappended hereto and not the foregoing detailed discussion of severalexamples of the present invention.

What is claimed is:
 1. A system for dispensing texture material in adesired spray pattern that substantially matches an existing texturepattern on a target surface, comprising: a container assembly definingan inner surface formed at least in part of a corrodible material; anactuator assembly defining an outlet opening having an adjustablecross-sectional area; and a concentrate comprising a solvent/carriercomprising water, wall texture material comprising at least one fillerand a resin/binder, a first anti-corrosion material, where the firstanti-corrosion material is a phosphate ester, and a secondanti-corrosion material, where the second anti-corrosion material issodium nitrite; wherein the concentrate is disposed within the containerassembly such that the water is exposed to the inner surface of thecontainer assembly; at least one of the first and second anti-corrosionmaterials forms a film on the inner surface of the container assemblywhile the concentrate is stored within the container assembly, where thefilm inhibits corrosion of the corrodible material forming at least partof the inner surface of the container assembly; the concentrate passesthrough the outlet opening in a spray pattern that forms the desiredtexture pattern on the target surface; and the first and secondanti-corrosion materials together comprise 0.125-7.00% by weight of theconcentrate.
 2. A system as recited in claim 1, in which: the firstanti-corrosion material comprises 0.1-5.0% by weight of the concentrate;and the second anti-corrosion material comprises 0.025-2.00% by weightbased on total weight of the concentrate.
 3. A system as recited inclaim 1, in which: the solvent/carrier comprises 25-65% of by weightbased on total weight of the concentrate; and the at least one fillercomprises 20-70% by weight based on total weight of the concentrate. 4.A system as recited in claim 1, in which: the solvent/carrier comprises38-58% of by weight based on total weight of the concentrate; and thewall texture material comprises 41-61% by weight based on total weightof the concentrate.
 5. A system as recited in claim 1, in which: thesolvent/carrier comprises 25-45% of by weight based on total weight ofthe concentrate; and the filler comprises 48-68% by weight of theconcentrate.
 6. A system as recited in claim 1, in which: thesolvent/carrier comprises 47-67% of by weight based on total weight ofthe concentrate; and the wall texture material comprises 31-51% byweight based on total weight of the concentrate.
 7. A texture materialconcentrate to be dispensed in a desired spray pattern from a containerassembly defining an inner surface formed at least in part of acorrodible material using an actuator assembly defining an outletopening having an adjustable cross-sectional area, where the desiredspray pattern that substantially matches an existing texture pattern ona target surface, the texture material concentrate comprising: asolvent/carrier comprising water, wall texture material comprising atleast one filler and a resin/binder, a first anti-corrosion material,where the first anti-corrosion material is a phosphate ester, and asecond anti-corrosion material, where the second anti-corrosion materialis sodium nitrite; wherein the concentrate is disposed within thecontainer assembly such that the water is exposed to the inner surfaceof the container assembly; at least one of the first and secondanti-corrosion materials forms a film on the inner surface of thecontainer assembly while the concentrate is stored within the containerassembly, where the film inhibits corrosion of the corrodible materialforming at least part of the inner surface of the container assembly;the concentrate passes through the outlet opening in a spray patternthat forms the desired texture pattern on the target surface; and thefirst and second anti-corrosion materials together comprise 0.125-7.00%by weight of the concentrate.
 8. A texture material concentrate asrecited in claim 7, in which: the first anti-corrosion materialcomprises 0.1-5.0% by weight of the concentrate; and the secondanti-corrosion material comprises 0.025-2.00% by weight based on totalweight of the concentrate.
 9. A texture material concentrate as recitedin claim 7, in which: the solvent/carrier comprises 25-65% of by weightbased on total weight of the concentrate; and the at least one fillercomprises 20-70% by weight based on total weight of the concentrate. 10.A texture material concentrate as recited in claim 7, in which: thesolvent/carrier comprises 38-58% of by weight based on total weight ofthe concentrate; and the wall texture material comprises 41-61% byweight based on total weight of the concentrate.
 11. A texture materialconcentrate as recited in claim 7, in which: the solvent/carriercomprises 25-45% of by weight based on total weight of the concentrate;and the filler comprises 48-68% by weight of the concentrate.
 12. Atexture material concentrate as recited in claim 7, in which: thesolvent/carrier comprises 47-67% of by weight based on total weight ofthe concentrate; and the wall texture material comprises 31-51% byweight based on total weight of the concentrate.
 13. A texture materialconcentrate as recited in claim 7, in which the solvent/carriercomprises 25-45% of by weight based on total weight of the concentrate.14. A method for dispensing texture material in a desired spray patternthat substantially matches an existing texture pattern on a targetsurface, comprising: providing a container assembly defining an innersurface formed at least in part of a corrodible material; supporting anactuator assembly defining an outlet opening having an adjustablecross-sectional area relative to the container assembly; and providing aconcentrate within the container assembly, the concentrate comprising asolvent/carrier comprising water, wall texture material comprising atleast one filler and a resin/binder, a first anti-corrosion material,where the first anti-corrosion material is a phosphate ester, and asecond anti-corrosion material, where the second anti-corrosion materialis sodium nitrite, where the first and second anti-corrosion materialstogether comprise 0.125-7.00% by weight of the concentrate; arrangingthe concentrate within the container assembly such that the water isexposed to the inner surface of the container assembly, and at least oneof the first and second anti-corrosion materials forms a film on theinner surface of the container assembly while the concentrate is storedwithin the container assembly, where the film inhibits corrosion of thecorrodible material forming at least part of the inner surface of thecontainer assembly; and operating the actuator assembly such that theconcentrate passes through the outlet opening in a spray pattern thatforms the desired texture pattern on the target surface.
 15. A method asrecited in claim 14, in which: the first anti-corrosion materialcomprises 0.1-5.0% by weight of the concentrate; and the secondanti-corrosion material comprises 0.025-2.00% by weight based on totalweight of the concentrate.
 16. A method as recited in claim 14, inwhich: the solvent/carrier comprises 25-65% of by weight based on totalweight of the concentrate; and the at least one filler comprises 20-70%by weight based on total weight of the concentrate.
 17. A method asrecited in claim 14, in which: the solvent/carrier comprises 38-58% ofby weight based on total weight of the concentrate; and the wall texturematerial comprises 41-61% by weight based on total weight of theconcentrate.
 18. A method as recited in claim 14, in which: thesolvent/carrier comprises 25-45% of by weight based on total weight ofthe concentrate; and the filler comprises 48-68% by weight of theconcentrate.
 19. A method as recited in claim 14, in which: thesolvent/carrier comprises 47-67% of by weight based on total weight ofthe concentrate; and the wall texture material comprises 31-51% byweight based on total weight of the concentrate.